Audi Workshop Service and Repair Manuals

Dismantling and assembling Torsen housing

Special tools and workshop equipment required

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Press tool -VW 408 A-

t	Press tool -VW 412-

t	Press tool -VW 454-

t	Press tool -VW 554-

t	Punch -2005-

t	Thrust piece -2050-

t	Drift sleeve -30 - 100-

t	Torque wrench -V.A.G 1331-

t	Extractor tool -T20143-

t	Thrust piece -T40106-

t	Shim -016 311 391 A-

t	Locking fluid -AMV 185 101 A1-

t	Sealing grease -G 052 128 A1-

Due to the introduction of an oil seal with additional dust lip (from serial no. 42987) → Fig., the flange shaft → Item was fitted with a groove. Refer to → Electronic parts catalogue “(ETKA)” to allocate components.

1 -	Flange shaft

q	Pressing out → Fig. or → Fig.

q	Pressing in → Fig.

q	Modification: from serial no. 42987 with groove → Fig.

q	Select components from → Electronic parts catalogue “ETKA”.

2 -	Bolt, 20 Nm + 90°

q	For vibration damper

q

3 x

q	Self-locking

q

Renew

3 -	Vibration damper

q	Not fitted on all versions

4 -

Oil seal

q	Removing → Fig.

q	Installation up to serial no. 42986 → Fig.

q	Modification: with additional dust lip from serial no. 42987 onwards → Fig.

q	Installation from serial no. 42987 onwards → Fig.

5 -	Torsen housing

q	Removing and installing (with gearbox removed) → Chapter

q	Removing and installing is also possible with gearbox installed in vehicle → 6-speed manual gearbox 0A3, four-wheel drive; Rep. Gr.34

6 -	Ball bearing

q	For flange shaft

q	Pressing out → Fig.

q	Pressing in → Fig.

7 -

Circlip

Pressing out flange shaft (Torsen housing with vibration damper) –  Remove circlip before pressing out flange shaft. –  Set up Torsen housing in such a way that flange shaft does not make contact with press plate -arrows- when it is pressed out.

Pressing out flange shaft (Torsen housing without vibration damper) –  Remove circlip before pressing out flange shaft.

Pressing in flange shaft –  Secure vibration damper before pressing in flange shaft.   Note Fit a flange shaft with a groove → Fig., when installing an oil seal with additional dust lip → Fig.. Refer to → Electronic parts catalogue “(ETKA)” to allocate components. –  Fit circlip.

From serial no. 42987 onwards: flange shaft with groove -arrow A- and oil seal with additional sealing lip -arrow B-   Note Oil seals with additional sealing lip -arrow B- must be fitted in conjunction with flange shafts which have a groove -arrow A-.

Levering off the oil seal.

Identification of oil seal versions A -  Oil seal - to serial No. 42986 - without additional dust lip -arrow 1-. B -  Oil seal - from serial No. 42987 onwards - with additional dust lip -arrow 2-.

Installing oil seal - to serial no. 42986 A -  Shim -016 311 391 A- (1.4 mm thick) B -  Oil seal –  Place shim and oil seal on tool as shown. l  Installation position: open side of oil seal points towards Torsen housing –  Lightly oil outer circumference of new oil seal.

–  Knock in new flange shaft oil seal as far as the stop; keep seal straight when installing. –  Pack space between sealing lip and dust lip half-full with sealing grease -G 052 128 A1-. –  Remove tool and shim.

Installing oil seal - from serial no. 42987 - with additional dust lip l  Installation position: open side of oil seal points towards Torsen housing –  Lightly oil outer circumference of new oil seal. –  Knock in new flange shaft oil seal as far as the stop; keep seal straight when installing. –  Pack space between sealing lip and dust lip half-full with sealing grease -G 052 128 A1-.

Pressing out ball bearing for flange shaft

Pressing in ball bearing for flange shaft